DIY Shifter Boss Jig
#1
Thread Starter
Senior Member



Joined: Jan 2015
Posts: 5,836
Likes: 3,421
From: Los Angeles
Bikes: 82 Medici, 85 Ironman, 2011 Richard Sachs
DIY Shifter Boss Jig
One at a time was TWO much trouble last time. As in I had to do one of them twice because the alignment wasn't. What is the simplest way to get the two lined up and perpendicular to the frame prior to brazing? A C-clamp is not working for me.
__________________
I don't do: disks, tubeless, e-shifting, or bead head nymphs. But I do hate all e-bikes.
I don't do: disks, tubeless, e-shifting, or bead head nymphs. But I do hate all e-bikes.
#2
Old fart



Joined: Nov 2004
Posts: 26,401
Likes: 5,333
From: Appleton WI
Bikes: Several, mostly not name brands.
I've never used a fixture for lever bosses on frames I build at home. I scribe a centerline on both sides of the tube, measure the distance from the headtube to where the boss should go, flux everything up and place the boss centered on the lines, and braze. A little weight on the boss (like the handle of an old file) will keep the boss from wandering as the flux boils. More weight risks distorting the tube.
We used a fixture for lever bosses at Trek, but that was so we could crank out dozens of them. For a one-off frame, I wouldn't bother.
We used a fixture for lever bosses at Trek, but that was so we could crank out dozens of them. For a one-off frame, I wouldn't bother.
#3
Senior Member


Joined: Feb 2012
Posts: 19,373
Likes: 5,515
From: Rochester, NY
Bikes: Stewart S&S coupled sport tourer, Stewart Sunday light, Stewart Commuting, Stewart Touring, Co Motion Tandem, Stewart 3-Spd, Stewart Track, Fuji Finest, Mongoose Tomac ATB, GT Bravado ATB, JCP Folder, Stewart 650B ATB
Do one at a time. Locate and braze one side, clean up enough to prep the other side and do that one next.
Long ago I made a simple fixture for 28.6 tubes to hole both lever bosses at the same time. Driven by wanting to make it easier/faster. Didn't use it for many years and finally recycled it into other tools. Just a couple of years ago I could have used it again... Andy
Long ago I made a simple fixture for 28.6 tubes to hole both lever bosses at the same time. Driven by wanting to make it easier/faster. Didn't use it for many years and finally recycled it into other tools. Just a couple of years ago I could have used it again... Andy
__________________
AndrewRStewart
AndrewRStewart
#4
Senior Member


Joined: Aug 2012
Posts: 681
Likes: 283
From: Seattle
This is how I'm doing it on a current project: If you follow the link you'll see the development of it. I am scratching a line down the side of the DT, then aligning a center mark at both ends to make sure it's straight and even to the other side.
by https://www.flickr.com/photos/54319503@N05/, on Flickr
__________________
https://www.flickr.com/photos/54319503@N05/
https://www.draper-cycles.com
https://www.flickr.com/photos/54319503@N05/
https://www.draper-cycles.com
#5
Senior Member

Joined: Dec 2019
Posts: 1,196
Likes: 394
I just use the Mark I eyeball. After tacking pick the frame up and have a good look round from every angle to make sure. Maybe it would help to just hold them in position first with one hand and do a couple of little sharpie marks because it might be easier to see in that position.




